KFI 101690 User manual

©2019 Copyright Kappers Fabricating, Inc. All rights reserved 1
POLARIS RZR TURBO S
Kit Components:
Item # Qty. Description
1 1 Winch Mount
2 1 Support Bracket
3 1 Fairlead Adapter
4 1 Bolt Plate
5 1 HK-031 (UTV Mini Rocker Kit)
6 1 HK-190 (Winch Mount Hardware Kit)
6.1 3 3/8”-16 x 1.00 Hex Bolt Flange
6.2 3 3/8”-16 Hex Nut Flange Nylock
6.3 2 M10-1.50 x 25 Hex Bolt Flange
6.4 4 M8-1.25 x 16 Hex Bolt Flange
6.5 1 5/16”-18 Hex Nut Flange Nylock
1. Removethehoodusingthetwohoodlatches.
ShowninFigure2.
2. Detachfrontfasciabyremovingthe2TorxBolts
(A).ShowninFigure2.Discardfascia.
3. Removetowhook(B)showninFigure3save
hardwaretoreinstalllateranddiscardthetowhook.
NOTE:Tapethebackerplatetokeepitfromfalling
down.
4. Place bolt plate (4) through slot in frame and use
one 5/16” nut (6.5) to secure. Make sure threaded
nuts are centered in the holes.Figure4
INSTALLATION INSTRUCTIONS:
“Figure 1”
1
2
3
4
B
Backer Plate
6.4
6.3
6.5
6.2
6.1
Threaded Nuts
Slot
Threaded Nuts 6.5
“Figure 4” Bolt Plate Installation
“Figure 3” Tow Hook Removal
Winch Mount PART # 101690
“Figure 2” Hood & Front Fascia Removal
HOOD
LATCH
A

©2019 Copyright Kappers Fabricating, Inc. All rights reserved 2
5. This mount comes with a wide fairlead opening. If
you have a standard or 2 hole winch you will need to
install the wide to standard adapter plate (3) Figure 5 .
If you have a wide winch you will not need the standard
adapter plate (3). Mount roller/hawse fairlead to bumper
according to your winch manual. Figure 1&5
6. Loosely bolt support bracket (2) and winch mount (1)
together with four M8 bolts (6.4). Figure 1, 5 & 7
7. Install your winch upside down to the winch mount (1)
using the hardware provided with your winch. Figure
6,7 shows a standard winch bolt pattern 3”x 4 7/8”. Use
the outside set of holes for a wide winch 3”x 6.60” and
the center set of holes for a 2 hole winch. Motor will be
on the drivers side with clutch on the passenger side.
8. Install winch and winch mount assembly (1) & (2) to
bolt plate (4) installed in step 4 using the two included
M10 Hex Bolts (6.3) Figure 8
“Figure 6” Winch installation
9. Reinstall tow hook hardware (E) removed from step 3
Figure 9
10. Tighten all hardware
1
2
“Figure 5” Fairlead installation
3
6.4
E
“Figure 9” Tow Hook
Hardware Reinstall
6.3
“Figure 8” Winch Mount
Assembly
Wide 2 Hole
Motor
Clutch
1
2
6.4
“Figure 7” Winch bolts
(Shown with standard winch)
Motor
Clutch

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WIRING INFORMATION
1. For power location (G) please see Figure 10. The contactor
will mount below arrow (F) in Figure 10 on this machine. You
will see four formed holes on the fire wall.
2. Wire your winch per your winch installation instruction.
3. Route winch switch wiring from contactor to the switch panel
(H). Please see winch owners manual wiring instruction for
dash rocker or mini rocker.
4. Mini-Rocker Switch Hardware Kit (HK-31). This allows you
to mount your usual handle bar mounted switch to almost any
desired location.
a. Remove handlebar mount hardware from the switch.
b. Locate desired mounting location.
c. Mark and drill two switch holes through dash
using switch housing as a template.
d. Drill a 3rd hole for the switch wiring.
e. Assemble per figure 12 using HK-031 hardware.
5. Find a location that suits your purposes for the mini rocker
switch and hand remote.
“Figure 12” Mini-Rocker Mounting
F
G
“Figure 10” Power & Ground Under hood
When installing your switch in the dash
panel, use dash rocker switch as template
as some machines have larger switch
templates.
CAUTION
“Figure 11” Switch Panel
H
Positive Battery (+)
Negative Battery (-)
Keyed (12v) /Accessory